Mattress or the like



Dec. 23, 1347? E, L. PAB ST 2,433,321

MATTRESS OR THE LIKE Filed Jail. 10, 1944 Patented Dec. 23, 1947 MATTRESS OR THE LIKE Edwin L. Pabst, Cincinnati, Ohio, assignor to Spring-Air Company, Holland, Mich., a corporation of Michigan Application January 10, 1944, Serial No. 517,697

7 Claims.

The present invention relates to cushion pad structures such as mattresses and the like and comprises an improvement in the construction described and claimed in my copending United States patent application Serial No. 472,511, filed January 15, 1943, issued April 3, 1945, as Patent No. 2,373,047.

The structure to which the invention relates is the'type in which an outer casing, such as a mattress ticking, is compartmented by spaced parallel partition sheets extending between and secured to the top and bottom panel sheets, generally crosswise of the assembly, with resilient material such as cotton, hair, rubber or the like filling the compartments. Patent No. 2,373,047 describes and claims certain improvements in the relative arrangement of the outer casing and the inner partition sheets, and in the method of assembly. The present invention introduces further improvements which may be combined with those of the earlier application or may be used independently thereof.

Important objects of the present invention are to reduce the-cost of manufacture of cushion pads of the type indicated, to strengthen the construction, to render it more durable in use, and to eliminate puckering and unevenness in the newly made product as well as the tendency to become puckered and uneven due to stretching of the fabric after a period of use.

The foregoing and other objects and advantages will be apparent to those skilled in the art from the following specification, taken in conjunction with the appended drawing, in which I disclose a preferred form of embodiment of the invention. It is to be understood that this embodiment is selected merely to illustrate the invention in a form which I now prefer and have found eminently satisfactory in actual practice. This disclosure is not to be taken as limiting the inventive features to the precise form in which they are disclosed. On the contrary, these features are susceptible of modification within the broad spirit of the invention as defined by the appended claims; moreover the novel features need not be used in the combinations in which they are embodied in the illustrated form, since some of them are capable of independent use.

In the accompanying drawing,

Figure 1 is a top plan View, broken away for economy of space, of a top or bottom mattress panel sheet showing the lines along which the sheet is folded to introduce the tucks which form an important feature of the invention;

2 is a similar view of the sheet after the 2 stitching operation by which the tucks are formed;

I Fig. 3 is a similar view showing the panel sheet after the partition sheets are sewed to the tucks;

Fig. 4 is a detail view showing an end portion of one of the tucks in side elevation;

Fig. 5 is a fragmentary perspective view of an assembly of top and bottom panel sheets showing the spaced relation in the finished product;

Fig. 6 is a cross sectional View of one side portion of a mattress showing the complete assembly of top and bottom panel sheets, a partition sheet and a side wall sheet; I

Fig. 7 is a similar view showing the side wall panel sheet and partition sheet connected in a different manner from that shown in Fig. 6;

Fig. 8 is a perspective view of a finished mattress; and

Fig. 9 is a detail cross sectional view taken on the line 9-9 of Fig. 8.

Referring now to the drawing, where the invention is shown disclosed in a bed mattress, Fig. 1 shows a panel sheet I0 which is rectangular in shape and made of any durable fabric as is usual in the making of mattress ticking. Two of these panel sheets are used, one for the top of the mattress and one for the bottom. The sheet In in Fig. 1 may be considered to be the top sheet and it differs from the corresponding sheet shown in my Patent No. 2,373,047 only by being about two inches longer for incorporation in a finished mattress of the same size as the one shown in that patent. This extra length is necessitated by the provision of spaced parallel tucks, preferably arranged transversely of the sheet, to provide attaching surfaces for compartment partition sheets as will now be described.

In Fig. 1 the numerals II, II indicate lines, which may be and preferably are imaginary lines, along which the sheet is folded to provide the tucks 12 (Figs. 4 and 5). The line I3 in Fig. 1 indicates the juncture of the two plies which constitute the tuck, this line appearing also in Fig. 5. It will be understood that Fig. 1 depicts the unfolded blank, while Fig. 2 shows the finished blank with the tucks incorporated in it by a line of stitching 14 at the base of each tuck, securing the two plies together.

Fig. 3 shows the finished sheet with the margins of the partition sheets I5 sewed by a lap seam to the flanges or ribs provided by the tucks [2. This connection is made by a line of stitching l6 spaced to be slightly inwardly of the line of stitching 14 which formed the tucking relationship of the two plies.

The tucked sheet will be found reduced from its originally eXCess length to the length of the desired mattress, the excess material being used in the tucks. The partition sheets are sewed to the tucks and the edges of the sheet are then sewed to end and side wall sheets l1, I8 respectively to form a finished box structure having compartments defined by adjacent partition sheetsaadapte ed to bestufied with any conventional filling. The end portions of the partition sheets l may be notched out, as shown at I9 and as disclosed in Patent No. 2,373,047, for the purposesthere. fully explained. When the mattress is filled'and sewed closed the product willfbeafoundttobeune. usually durable and substantial becausethe topand bottom panel sheets present no lines of surface stitching where the partition.-sheets -are,con-- nected to them. The connecting lines of stitching it are concealed within the structure; as best appears in Fig. 9, and being thus concealed they are protected from injury, The lines-oi stitching- [4 which fix the tucks are likewise concealedAvithin the structure so that they too, areprotected from damage. The assemblingoperation is-great. 1y facilitated because itis much' easieh tosowthe margins of the partition sheets; i5 tov the-ribs formed by the tucks l2;than to perform-thetype of sewing shown in this: part of; the. structure-as; disclosed in Patent No. 2, 3-733047, and, as previe ously practiced. Moreover; it. is; easierto; place properly the tucks in ablank flatrsheetzthanato. sew the partition sheetsalongstraightandequally' spaced parallel lines in a sheetoi:mattresatiching;.

In addition to the foregoing; advantages? the double plies of the tucks provide-strengthening: ribs which tend to maintainthe. mattress against; distortion resulting from stretching-oi the. mattress.

The structure is thus morereadily-made and is stronger and more durable in use than: any conventionally made prior; art device; with: which I am acquainted. Constructed ass. thus: far. (16:- scribed the invention obviouslyrhasconsiderable merit and novelty, but Iprefer to -intr,odnce-,c.er.-- tain further improvements which are; productive. of additional advantages; These; will; nowbeedee scribed.

I prefer to deepen the tucks; l2'galong'the-end. portions of each, i. e., along; the,v side: marginal: zones of the mattress, as .shown atpzfii'in -Eigs. 5 and 6. When the partition .ShBfilESJ fiiarenotched at their corners as is; preferred, thesed'eepened: or widened portions of the, tucksaextend-into the cut out areas Iii. They are-notuoined to the partition sheets, but they have the-efieots of'taking up excess material from/the. length-.ofrthe-panel' sheets so that the original overallzlength of theside marginal zones of the panelisheetsis less than that of the intermediate zone-thereof. I have attempted inFigs. 2 and 3 to'illustratetheefiect the stippling 2 I. The-arrangement permits a predetermined degree 'ofcrowning of the intermediate zone of each-panelsheet resulting from the fact that the partition; sheets. I;5 hold. the intermediate zone-down or inwardly of; the mattress. There is less crowning, or none at all; along the side marginal zonesof the mattress., where the material is notheld downorinwardly by the partition sheets. If. itwere-not for the deepened or widened tuck portions 20. in these. side marginal zones the panel. material. would. pucker. The material ishowever. kellhstrai h and fiat by the novel arrangementrofdeepening: the tucks because the excess material,,-,is;therebyr removed from the plane of the panel sheet and tucked inwardly of the structure.

The efiect is sought to be illustrated in Fig. 8, where it will be observed that the intermediate area of the mattress is well crowned as is desirable in these constructions, while the side marginal zones taper down to an edge which is quite flat and. straight. This formation of the edge adapts it to receive very neatly the side and end wall sheets which are conventionally secured in place by usual border trimming Or cording 22.

The .end.edges of each partition sheet l5 may be connected to the side wall sheets [8 in the conventional manner, as shownin Patent No. 2 ,373,04T and in. Fig; 6 of the present application. However; I prefer'tozmake this connection in the samegenerahway asthe connection between the side margins of the partition sheets l5 and the panelisheets ID, i. e., by the use of tucks. This arrangement is shown in Fig. 7, where it will be noted tucks 23 aresewed into eachside wall sheet laa with-widened or deepened endv portions and the, intermediate portions are stitched'to the end margins of the partition-sheets; By deepening: the end portions; puckering of r the. margins 'of the sidewall sheets is eliminated, andtheusev of tucks tional features or constructionsv for any utilitarian:

afiords a strong, durable and easily made connection for the partition sheets and. the: sidewall sheets.

The mattress maybe trimmed insany-desirablep Way. and. adoption of the'process of t-hepresent: invention, in thewhole combination or any part: of. it, will be found to be productive, of-the ad-- vantages hereinabove asserted and-tomilitate in no wayagainst the incorporation of any convenor. ornamental purposes.

I.claim:

1. Acushion pad structure such as amattress, orthe like comprising substantially rectangular: top. and bottom panel sheets, a. plurality ofinwardly projecting spaced parallel tucks sewedinto. said sheets and extending substantially'entirely across the pad, partition sheets sewed; at: their' opposite margins to opposed pairs of; said tucks,

and filling disposed'in-the compartments defined by adjacent partition sheets, theportions of'said tucks. inthe side marginal zones of the structure.

beingv wider than theportionsrin, theintermediate: -3 zone whereby the structure is morehighly crowned;

initsintermediate, zone than along its" edges.

2.. A- substantially rectangular paneLsheet for use as the top or bottom surface-wallofiacushion pad structure such as a mattress or the like, said sheet having a, plurality of; spaced: parallel: tucks:

sewed int-o it-substantially entirely across its width forming inwardly projecting ribs or flanges to. which filling compartment partition sheets may be sewed, said tucks being wider along the marginal zones of the sheet thanin the-intermediatezone-whereby:thegpressure. of filling in astructure made from said-sheet will'cause the sheet to be more highly cr0wned5alongits intermediate zone than along-itseedges.

3-. A. cushion padstructure. suchas a mattress or the; lilre, comprising: substantially rectangulartop and bottom panelsheets, a pluralityof in wardly. projecting spaced-parallel tucks sewed into said sheets and extending across-the-pad, partition sheetssewed at their opposite margins to they intermediate portions only of opposed pairs of. said tucks :and'being: unconnected to the tucks in: the. side marginal zones of the structure, and

filling disposed in the compartments definedby- 7&5- adiacent. partition-sheets, said tucks being wider in said side marginal zones than in said intermediate portions whereby the structure is more highly crowned in its intermediate zone than along its edges and said side marginal zones are substantially coextensive in overall length with said intermediate zone.

4. A cushion pad structure such as a mattress or the like comprising substantially rectangular top and bottom panel sheets, means connecting said sheets to provide a plurality of parallel compartments, filling in said compartments, a series of tucks sewed into the sheets to which tucks said connecting means are sewed, said tucks extending substantially entirely across each sheet and extending to a greater depth across the side marginal zones than across the intermediate zone of each sheet whereby the intermediate zone of the sheet is more highly crowned than the side marginal zones.

5. A cushion pad structure such as a mattress or the like comprising top and bottom panel sheets and end and side wall sheets connecting the panel sheets to form a box ticking, partition sheets arranged in spaced parallelism across the structure and having their corners notched out and their end edges connected to the side wall sheets, a plurality of inwardly projecting spaced parallel tucks sewed into the panel sheets and extending across the pad to provide inwardly extending ribs or flanges, means connecting the side margins of each partition sheet between the notched out corners thereof to opposed pairs of said tucks,

and filling disposed in the compartments defined by adjacent partition sheets, said tucks being relatively narrow throughout the portions thereof which are connected to the partition sheets and being relatively wide throughout the portions thereof which extend into the notched out corners of the partition sheets, whereby the intermediate zones of the tucked panel sheets are originally longer than the marginal zones thereof but both zones are substantially coextensive in length in the finished structure due to the crowning of the intermediate zone resulting from expansive pressure of the filling.

6. A cushion pad structure such as a mattress or the like comprising top and bottom panel sheets and end and side wall sheets connecting the panel sheets to form a box ticking, partition sheets arranged in spaced parallelism across the structure and having their corners notched out, a plurality of inwardly projecting spaced parallel tucks sewed into the panel sheets and into the side wall sheets and extending across the pad and down the sides of the pad to provide inwardly extending ribs or flanges, means connecting the side margins of each partition sheet between the notched out corners thereof to opposed pairs of the tucks in the panel sheets, means connecting the end edges of each partition sheet to opposed pairs of the tucks in the side wall sheets, and filling disposed in the compartments defined by adjacent partition sheets, said panel sheet tucks being relatively narrow throughout the portions thereof which are connected to the partition sheets and being relatively wide throughout the portions thereof which extend into the notched out corners of the partition sheets, whereby the intermediate zones of the tucked panel sheets are originally longer than the marginal zones thereof but both zones are substantially coextensive in length in the finished structure due to the crowning of the intermediate zone resulting from expansive pressure of the filling.

7. A cushion pad structure such as a mattress or the like comprising top and bottom panel sheets and end and side wall sheets connecting the panel sheets to form a box ticking, partition sheets arranged in spaced parallelism across the structure and having their corners notched out, a plurality of inwardly projecting spaced parallel tucks sewed into the panel sheets and into the side wall sheets and extending across the pad and down the sides of the pad to provide inwardly extending ribs or flanges, means connecting the side margins of each partition sheet between the notched out corners thereof to opposed pairs of the tucks in the panel sheets, means connecting the end edges of each partition sheet to opposed pairs of the tucks in the side wall sheets, and filling disposed in the compartments defined by adjacent partition sheets, said tucks being relatively narrow throughout the portions thereof which are connected to the partition sheets and being relativel wide throughout the portions thereof which extend into the notched out corners of the partition sheets, whereby the intermediate zones of the tucked panel and side wall sheets are originally longer than the marginal zones thereof but both zones are substantially coextensive in the finished product due to the crowning of each intermediate zone resulting from expansive pressure of the filling.

EDWIN L. PABST.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date Re. 13,982 Heffner Sept. 21, 1915 1,014,261 Schmitt Jan. 9, 1912 1,579,074 Burton Mar. 30, 1926 1,725,479 Rissmann Aug. 20, 1929 1,865,043 Pittoni June 28, 1932 2,021,237 Karr Nov. 19, 1935 2,130,935 Thompson Sept, 20, 1938 2,332,957 Weisglass Oct. 26, 1943 2,373,047 Pabst Apr. 3, 1945 FOREIGN PATENTS Number Country Date 13,219 Great Britain June 13, 1898 434,037 France Jan. 23, 1912 500,136 France Dec. 8. 1919 

